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CSWIP 3.1 Welding Inspection

Manual Metal Arc Welding or Shielded Metal Arc Welding

TWI Training & Examination Services
Course Reference WIS 5
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Manual Metal Arc Introduction

The MMA welding Process was first developed in the late 19th century using bare wire consumables. MMA is a simple process in terms of equipment The process can by used in AC, DC+ or DC The process is a manual process and demands a skill from the welder. The process is widely used throughout the welding industry both for shop and site working conditions high

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MMA - Principle of operation

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MMA welding
Main features:
Shielding provided by decomposition of flux covering Electrode consumable Manual process

Welder controls:
Arc length Angle of electrode Speed of travel Amperage settings

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Manual Metal Arc Basic Equipment

Control panel (amps, volts) Electrode oven Electrodes Return lead Welding visor filter glass Power source Holding oven Inverter power source Electrode holder Power cables

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MMA Welding Plant

Transformer: Changes mains supply voltage to a voltage suitable for welding. Has no moving parts and is often termed static plant. Rectifier: Changes a.c. to d.c., can be mechanically or statically achieved. Generator: Produces welding current. The generator consists of an armature rotating in a magnetic field, the armature must be rotated at a constant speed either by a motor unit or, in the absence of electrical power, by an internal combustion engine. Inverter: An inverter changes d.c. to a.c. at a higher frequency.

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Constant Current Power Source (Drooping Characteristic)

100 90 80 70

O.C.V. Striking voltage (typical) for arc initiation

Voltage

60 50 40 30 20 10 20 40 60 80 100 120 130 140 160 180 200

Normal Operating Voltage Range

Amperage
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Constant Current Power Source (Drooping Characteristic)

100 90 80 70

O.C.V. Striking voltage (typical) for arc initiation Required for: MMA, TIG, Plasma arc and SAW > 1000 AMPS

Voltage

60 50 40 30 20 10 20 40 60 80 100 120 130 140 160 180

Normal Operating Voltage Range

Large voltage variation, e.g. + 10v (due to changes in arc length) Small amperage change resulting in virtually constant current e.g. + 5A.
200

Amperage
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Constant Current Power Source (Drooping Characteristic) The static characteristic:

Voltage (V)
OCV

Large variation in voltage lead to small variation for welding current consistent penetration

Long arc Short arc Arc voltage

Welding current

Current (A)
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Source (Drooping Factors to be considered when selecting a MMA power source: Characteristic)
type of current required amperage range required the primary type of power available the position in which welding will be done
Low OCV

Voltage (V)

High OCV

Greater change in current improves arc starting and avoid stubbing for low amperage applications

Long arc Normal arc Short length arc

Arc voltage

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Current (A)
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Constant Current Power Source (Drooping Characteristic)

Combined characteristic - the arc force option
Voltage (V)
OCV

Combined characteristic assist starting and avoid electrode stubbing should a welder use too short an arc length

Constant current

Trigger voltage

Constant voltage

Current (A)
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MMA Welding Variables

Voltage The arc voltage in the MMA process is measured as close to the arc as possible. It is variable with a change in arc length O.C.V. The open circuit voltage is the voltage required to initiate, or re-ignite the electrical arc and will change with the type of electrode being used e.g 70-90 volts Current The current used will be determined by the choice of electrode, electrode diameter and material type and thickness. Current has the most effect on penetration. Polarity Polarity is generally determined by operation and electrode type e.g DC +ve, DC ve or AC
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MMA Welding Checks

OCV open circuit volts A check should be made to ensure that the equipment can produce the OCV required by the consumable and that any voltage selector has been moved to the correct position Current & polarity A check should be made to ensure the current type and range is as detailed on the WPS Other variables Checks should be made for correct electrode angle, arc gap and travel speed Safety Check should be made on the current carrying capacity, or duty cycle of the equipment and all electrical insulation is sound and in place. Correct extraction systems should be in use to avoid exposure to toxic fume.
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MMA Welding Checks

The welding equipment A visual check should be made on the equipment to ensure it is in good working order The electrodes Checks should be made to ensure that the correct specification of electrode is being used, the electrode is the correct diameter and in good condition. Basic fluxed electrodes ensure the correct heat treatment is being carried out before use Rutile electrodes do not require pre-baking but should be stored in a dry condition. Cellulosic electrodes should not be dried

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MMA electrode holder

Collet or twist type

Tongs type with spring-loaded jaws

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MMA welding parameters

Welding current
approx. 35 A/mm of diameter governed by thickness, type of joint and welding position

Too low poor starting slag inclusions weld bead contour too high lack of fusion/penetration

Welding current

Too high spatter excess penetration undercut burn-through

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MMA welding parameters

Arc length = arc voltage
Too low arc can be extinguished stubbing Arc voltage Too high spatter porosity excess penetration undercut burn-through

Polarity: DCEP generally gives deeper penetration

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MMA welding parameters

Travel speed
Too low wide weld bead contour lack of penetration burn-through Travel speed Too high lack of root fusion incomplete root penetration undercut poor bead profile, difficult slag removal

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MMA welding parameters

Type of current:
voltage drop in welding cables is lower with AC inductive looses can appear with AC if cables are coiled cheaper power source for AC no problems with arc blow with AC DC provides a more stable and easy to strike arc, especially with low current better positional weld, thin sheet applications welding with a short arc length (low arc voltage) is easier with DC better mechanical properties DC provides a smoother metal transfer less spatter

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MMA - Troubleshooting

MMA quality (left to right) - current, arc length and travel speed normal; current too low; current too high; arc length too short; arc length too long; travel speed too slow; travel speed too high
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MMA welding typical defects

Most welding defects in MMA are caused by a lack of welder skill (not an easily controlled process), the incorrect settings of the equipment, or the incorrect use, and treatment of electrodes Typical Welding Defects: Slag inclusions Arc strikes Porosity Undercut Shape defects (overlap, excessive root penetration, etc.)

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Manual Metal Arc Welding (MMA)

Advantages:
Field or shop use Range of consumables All positions Portable Simple equipment High welder skill required High levels of fume Hydrogen control (flux) Stop/start problems Comparatively uneconomic when compared with other processes i.e MAG, SAW and FCAW
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Disadvantages:

some

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Any Questions

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Questions
Manual Metal Arc Welding
QU 1. State the main welding parameters of the MMA welding process QU 2. What type of power source characteristic is considered essential for a MMA welding plant? QU 3. Give the main advantages of the MMA welding process when compared to the MAG welding process QU 4. State the four criteria that will govern the number of weld passes in a MMA welded joint QU 5. State two types of electrical supply and give the advantages of each
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